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T Ta ab blle eo of fC Co on nt te en nt ts s
1. General
1.1 Using This Manual 1.2 Safety Notice
---------------------------------------------- 1-1 ---------------------------------------------- 1-1 ---------------------------------------------- 1-1 ---------------------------------------------- 2-1 ---------------------------------------------- 2-1 ---------------------------------------------- 2-1 ---------------------------------------------- 2-1 ---------------------------------------------- 3-1 ---------------------------------------------- 3-1 ---------------------------------------------- 3-1 ---------------------------------------------- 3-4 ---------------------------------------------- 3-5 ---------------------------------------------- 3-5 ---------------------------------------------- 3-5 ---------------------------------------------- 4-1 ---------------------------------------------- 4-1 ---------------------------------------------- 4-1 ---------------------------------------------- 4-4 ---------------------------------------------- 4-4 ---------------------------------------------- 5-1 ---------------------------------------------- 5-1 ---------------------------------------------- 5-1 ---------------------------------------------- 5-1 ---------------------------------------------- 5-1 ---------------------------------------------- 6-1 ---------------------------------------------- 6-1 ---------------------------------------------- 6-1 ---------------------------------------------- 6-1 ---------------------------------------------- 6-1 ---------------------------------------------- 6-1
2. Product Description
2.1 2.2 2.3 Product Description Product Main Features System Specifications
4.3 Alarm Control Unit Block Diagram 4.4 Settings and Control
5. DC Distribution
5.1 DC Cabling 5.2 5.3 Low Voltage Battery Disconnect (System equipped with PDU) Battery Connections (System equipped with PDU)
6. Installation
6.1 6.2 6.3 6.4 Preliminary Inspection System Mounting Module Installation Shelf Wiring
INDEX i
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6.6 Battery String Connections (System equipped with PDU)
---------------------------------------------- 6-1 ---------------------------------------------- 6-2 ---------------------------------------------- 6-2 ---------------------------------------------- 6-2 ---------------------------------------------- 7-1 ---------------------------------------------- 7-1
6.7 Temperature and Alarm Connections 6.8 EXT. Breaker trip signal I/P Connector Wiring
---------------------------------------------- 7-1 ---------------------------------------------- 7-1 ---------------------------------------------- 7-1 ---------------------------------------------- 7-1 ---------------------------------------------- 8-1 ---------------------------------------------- 8-1 ---------------------------------------------- 8-1 ---------------------------------------------- 8-1 ---------------------------------------------- 8-2 ---------------------------------------------- 8-2 ---------------------------------------------- 8-2 ---------------------------------------------- 8-3 ---------------------------------------------- 8-3 ---------------------------------------------- 9-1 ---------------------------------------------- 9-1 ---------------------------------------------- 9-1 ---------------------------------------------- 10-1 ~3
7.4 DC Load Connections 7.5 7.6 System Functionality Check System Operation
9. Maintenance
9.1 Cleaning and Maintenance 9.2 Removing and Replacing a Rectifier Unit
INDEX ii
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1 General
1.1 Using This Manual
This manual contains specifications and instructions to properly install and maintain the power supply system. Component specifications and drawings are also included. This manual contains information related to the operation and maintenance of the Alarm Control Unit (ALU), the 48V/+24V Power Supply Unit (PSU), and the Distribution Module. Additional information is provided on system status and alarms, troubleshooting, and system maintenance. Appendix figures of this manual contains drawings, simple block diagram for different functional blocks and systems schematic. Step-by-step procedures required for the installation and turn-up are detailed. All equipment parameter setting, adjustments, and confirmation, as well as system monitoring, operations, and maintenance procedures, are included. Warnings are printed in bold, italic lettering. They alert the installation or maintenance craftsperson of a potential hazard to either the equipment or the craftsperson if the warning is not followed.
Before installing the system, verify the AC input voltage and frequency, the AC breaker rating and type, and other environmental conditions as noted in the specifications. The system has passed stringent system testing prior to shipment. To avoid electrical shock. The rectifier system requires a single ground point permanently connected to earth ground. An AC breaker must provide adequate isolation between the system input and commercial AC main. The environment should be dust free and controlled by an AC system. flammable vapors or fluids. The area must be free of any
To avoid electrical hazard, the covers must not be removed on any component, including the ALU and the rectifier. Circuit breakers or fuses must be replaced with approved replacement circuit breakers meeting the original design specification. All connections must be made per the latest issue of the applicable national and local codes.
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2 Product Description
2.1 Product Description
This power Shelf consists of modular rectifiers, an Alarm Control Unit (ALU), and a DC distribution module. Up to four rectifiers and an alarm unit can be equipped on a shelf containing an integrated distribution module. The rectifiers can operate from a universal range of AC line voltages. The High Line (HL) operations are defined at an AC line input range of 165VAC~ 264VAC. The Low Line (LL) operations are defined at an AC line input range of 90 VAC-130 VAC. The system is controlled and monitored by the ALU. System level rectifier voltage settings, system status, and alarms are displayed on the ALU. The system float voltage, equalize voltage, and alarm thresholds are set from RMS. The ALU also provides automatic derating of the output power over the whole operating line voltages. Figure 1 shows different functional blocks of the system.
2.2
2.3
System Specifications
The system specifications are provided in the following sections.
2.3.1 -48V Standard Power Shelf Configuration(MODUL NAME: ES48/120-JAAxx) (1) AC Input: (2) (3) System Capacity: Rectifier: 175VAC ~ 275VAC, 48Amps. Max 120Amps. Max. -48V/30A1~4
(4) Control and Supervisory Unit Figure 1 shows a front view of shelf.
2-1
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2.3.2 +24V Standard Power Shelf Configuration(MODUL NAME: ES24/200-JAAxx) (1) AC Input: (2) (3) (4) System Capacity: Rectifier: Control and Supervisory 175VAC ~ 275VAC, 48Amps. Max 200Amps. Max. +24V/50A1~4
Figure 1 shows a front view of shelf. Environmental Data System Environmental Data Specification Operating temperature Storage temperature Humidity Altitude Weight Lightning/surge Seismic Safety 0 to +50 -40 to +70 0% to 95% RH -300 ft. to 10,000 ft. Approximately 48 lbs. ANSI/IEEE C62.41-1, and IEC 1000-4-5 Bellcore GR-63-CORE, Zone 4 CUL and UL Listed and Marked Value
2.3.3 -48V System with Power Distribution and Rectifiers(MODUL NAME: ES48/90-JBAxx) (1) AC Input: 175VAC ~ 275VAC, 36Amps. Max (2) (3) (4) (5) (7) System Capacity: Rectifier: Control and Supervisory Load Distribution: Battery Breaker: 30A Breaker5 @ Single Pole 100A1 90Amps. Max. -48V/30A1~3
(6) Low Voltage Disconnect Switch: 100A1 @ Single Pole at Battery Side (8) AC Breaker 2-2
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2.3.4 -48V System with Power Distribution and Rectifiers(MODUL NAME: ES48/90-JFAxx) (1) AC Input: 175VAC ~ 275VAC, 36Amps. Max (2) (3) (4) (5) System Capacity: Rectifier: Control and Supervisory Load Distribution: 100A Breaker4 @ Single Pole 90Amps. Max. -48V/30A1~3
(6) Low Voltage Disconnect Switch: 100A1 @ Single Pole at Battery Side Figure 1-1 shows a front view of shelf. Environmental Data System Environmental Data Specification Operating temperature Storage temperature Humidity Altitude Weight EMI/FRI Lightning/surge Seismic Safety 2.4 Electrical Data The system electrical data is provided in the following tables. 2.4.1 Input 0 to +50 -40 to +70 0% to 95% RH -300 ft. to 10,000 ft. Approximately 48 lbs. FCC Part 15, Class B and CISPR 22, Class B ANSI/IEEE C62.41-1, and IEC 1000-4-5 Bellcore GR-63-CORE, Zone 4 CUL and UL Listed and Marked Value
2-3
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Table 2 displays the system output specifications. Table 2 System Output Specifications Specification DC Volts Load regulation Line regulation Current Limit Current share Noise: Audio band Wide band Acoustic 2.4.3 Status/Alarm Indicators The Power Shelf has the following status/alarm indicators: Load Current AC ON Rectifier Fail Alarm (RFA) Current Limit (CL) Float/Equalize (FL/EQU) Major Alarm (MAJ) Minor Alarm (MIN) High Voltage Alarm (HV) High Voltage Shutdown (HVSD) Low Voltage Alarm (LV) Low Voltage Disconnect Open (LVDS OPEN) Fuse Blown (FUSE ALM) AC Fail (AC FAIL) Value 38~60 VDC (-48V Version) 20~30 VDC (+24V Version) <1% <0.2% 110% <5% <2mv <10 mVrms <55 dBA
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3.2 Specifications
Detailed rectifier specifications are provided in the following sections. 3.2.1 Electrical Detailed electrical specifications for the rectifier are provided in this section. 3.2.1.1 Input Table 6 displays the rectifier input specifications. Table 6 Rectifier Input Specifications Specification Input Voltage Input Current Line Frequency Power Factor THD Efficiency Inrush Current Value 90VAC to 275VAC, Single Phase, (during 176 to 150VAC derated to 80% Load, during 150 to 90VAC derated to 50% Load) 12 Amps at 176 VAC, Full Load 45 to 65 Hz >0.99, at 220 VAC Input, Full Load <5%, at 220 VAC Input, Full Load >90%, Full Load (-48V Version) >88%, Full Load (+24V Version) <12 Amps (peak), 220 VAC, Full Load, Cold Start
3-1
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DC Output Voltage
Output Power Regulation: Load Line Current Limit Noise: Audio Band Wide Band Acoustic Current Sharing Dynamic Response Protection 3.2.1.3 Protection
Table 8 displays the protection specifications. Table 8 Protection Specifications Condition Response
High Output Voltage (Exceeds Automatic Shutdown and Latch Preset Value) Over Current/Output Short Over Temperature Brownout AC Input Voltage High AC Input Voltage Low Automatic Shutdown and Recovery Automatic Shutdown and Recovery No Damage Automatic Shutdown and Recovery Automatic Shutdown and Recovery
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3-3
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3.3.2 Float Voltage Adjustment Verify the required float voltage setting per battery manufacturer specification. If the factory setting differs from the battery manufacturer recommended setting, the ALU float voltage parameter and each rectifiers float voltage must be adjusted to the new setting. A digital multimeter and a small screwdriver are required to perform this procedure. Located the float voltage access point (FL) at the front of the rectifier. To adjust the float voltage, perform the following steps: 1. Remove the ALU.
3-4
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3.3.3 Current Limit Setting Warning: Current limit setting is not intended to be adjusted in the field. Users should only use it for their reference. Current limit adjustment is made by turning the CL variable resistor with the digital multimeter probes in the I+, I- test points. This current limit is set at the factory. The factory setting is always the maximum value of 110%. For a 48V/30 Amp rectifier, the computation for the current limit is 1.130=33 Amps. The following adjustment procedure is for reference only: 1. 2. 3. At the rectifier, place the digital multimeter probes in the I+, I- test points. Place a small screwdriver in the CL adjustment point. Turn the variable resistor counterclockwise to increase the value. clockwise to decrease the current limit value. Turn the variable resistor
The 400 VDC bus voltages is modulated at a frequency higher than 100KHz and stepped down through a transformer. Output of this transformer is rectified and filtered to provide the output DC voltage.
3-5
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4.2 Specifications
4.2.1 Input Characteristics Table 14 displays the input characteristics. Table 14 Input Characteristics Characteristic Input Voltage Range Input Current 4.2.2 Push Buttons This alarm unit has 3 push buttons on the front panel. These push buttons are used to control the alarm unit. Following are possible functions these buttons will act: Control FL/EQU HVSD RST SMR RST Voltage/Current Display Value 40V to 59.5V for 48V system 20V to 30V for 24V system <0.5 Amps
4-1
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Settings FL/EQU - Function HVSD RST - Function SMR RST - Function Voltage/Current - Function
Description - This button is used to manually select SMR into float or equalize state. - When SMRs shut down resulting from DC high voltage. used to reset alarm state. This button is
System will detect RFA warning when SMRs are vacant or turned off. However, if the button is pushed at this time, the system will stop sending the warning. This button is used to change the voltage or current of LED display.
Notice: When SMR turn off , the system will detect RFA warning in ES48/90-JFAxx. When SMR vacant , the system will detect RFA warning in other system. 4.2.3 Indicators Table 15 displays the ALU indicators. Table 15 ALU Indicators Indicator LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8 LED9 LED10 4.2.4 Relay Output Table 16 displays the relay output.(Please refer to Figure 5) Table 16 Relay Output Relay Relay1 Relay2 Relay3 Relay4 Function ACF MAJ HVSD HV Description AC Failure Major Alarm High Voltage Shutdown DC High Voltage Alarm-Minor Relay Relay5 Relay6 Relay7 Relay8 Function LV LVD FA MIN Description DC Low Voltage Alarm-Minor Low Voltage Disconnect Open Breaker Trip Alarm Minor Alarm Color Green Yellow Red Red Yellow Red Red Red Red Red Function FL EQU HV LV MIN MAJ HVSD AC FAIL FUSE ALM System Float State System Equalize State DC High Voltage Alarm-Minor DC Low Voltage Alarm-Minor System Minor Alarm System Major Alarm High Voltage Shutdown (DC) Loss of AC Input DC Output or Breaker SW. Trip Description
4-2
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Minor Alarm (1) (2) (3) (4) One rectifier fail. Current Limit Alarm. DC High Voltage Alarm. DC Low Voltage Alarm. The alarm condition exists when the DC output voltage is higher than the parameter setting. The alarm condition exists when the DC output voltage is lower than the parameter setting. The alarm condition exists when the AC voltage is absent. The alarm condition exists when the DC output voltage is lower than the threshold voltage. (System equipped with PDU) The alarm condition exists when the battery switch trip off or the DC Load output switch trip off.
Table 18 displays the ALU mechanical data. Table 18 ALU Mechanical Data Dimension Height Depth Width 5.2 in. (132mm) 9.9 in. (251.3mm) 1.9 in. (46.2mm) Value
4-3
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4.2.8 Remote monitoring and control The ALU provide the flowing remote monitoring methods. 1. 2. Use RS232 Interface. Use Internet Web server function (RJ45)-(Optional)
4.2.10 Parameter Modify Enter the Remote monitoring software or use the internet Brower to modify the parameter.
Comment
Steps LVDS Trip Voltage Function Default Recovery Steps Compensation On/Off Function Setting Default Compensation Volt. Range Function Default Steps Equalize Duration Time Function Default Steps Mains Recovery Charging Current Limited
Sets LVDS trip voltage 42VDC (-48V System) 22VDC (+24V System) When one rectifier work normally and not in the CL Mode - 0.1V
Enable / Disable Temperature Compensation feature - ON/OFF - On To set Temperature Compensation Voltage -1.3VDC~+1.3VDC (-48V System) -0.7VDC~+0.7VDC (+24V System) 0.1V To set the duration of equalizes charging after AC recovery. This setting is active when battery deeply discharge resulting from AC fail. 1-10 hours 1 hour When mains recovery to avoid the charging current too large, CSU will limit the charging current. [ (IL+ Max. Cap.) / Parameter] / available SMR 4-5
Control: Settings Remote SMR On/Off - Function Description Description Floating / Equalize control - Function Description Comment
Remote SMR on/off capability exists through the SMR Shutdown (1-3) CSU control. CSU automatically shuts down SMR in case of DC high voltage. Users can manually shut down SMR from Remote Management System. SMR floating/equalize status can be set through the CSU control. CSU automatically transfer SMR to floating mode in case of mains recover after deep discharge resulted from blackout/battery test Users can manually set SMR to floating or equalize from CSU. When system HVSD alarm recovery and system voltage reduce to normal, this function is used to reset the HVSD alarm
4-6
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5 DC Distribution
5.1 DC Cabling
You can find DC output which marked Load + and Load behind the shelf of the left hand side.
5-1
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6 Installation
6.1 Preliminary Inspection
Prior to removing the system from the crate, note any damage to the carton. Remove the system from the packaging and inspect the shelf and components for any dents or damage. If any damage is noted, contact the carrier immediately.
6-1
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2. Each alarm connection is provided with a normally close relay contact. This contact is capable of carrying 0.5 Amp DC at 30VDC on a continuous basis. 3. Warning: All external circuits connected to these alarm relay terminals must be secondary and properly isolated from the incoming line.
6.8
Connect the PDU signal cables to the rear of the shelf which are mark EXT. Breaker trip signal I/P connector.
The FUSE ALM LED on the front panel of ALU will light up when the breaker open.
6-2
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7-1
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8-1
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8-2
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Warning: Ensure that the device rating does not exceed the branch load wire capacity. If the device rating is higher than the branch load wire rating, the branch load wire must be changed to a larger wire. Failure to protect the branch load wire may result in overheating and fire.
8-3
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9 Maintenance
9.1 Cleaning and Maintenance
9.1.1 General Special maintenance is not necessary for this system, unless the system is being operated in a severely harsh environment (dusty environment). The front panels and the cover of the DC distribution cabinet were treated with a special coating. Do not use organic cleanser or volatile solvent because corrosion damage may occur. For periodic cleaning, brush the dust from the cover and panel. If necessary, use a gentle cleanser or a lightly dampened lint free cloth to remove any dirt or smudges. 9.1.2 Periodic Maintenance Periodic maintenance is not required for normal operation. If necessary, wipe dust from the front of the power system using a lint free, soft cloth and gently wipe the front of the distribution module, the ALU, and the rectifiers. If necessary, use a gentle detergent to clean. Warning: Do not use a spray cleanser to clean the equipment. Using a spray cleanser directly on the equipment can result in serious equipment damage.
9.2.2 Replacing a Rectifier To replace a rectifier, perform the following steps: 1. 2. Make sure the breaker on the front panel of PSU is switched off. Install the rectifier unit carefully. Place the rectifier on the shelf, ensuring that the rails are on the track.
Warning: Do not force the module into the slot. If does not slide in and connect easily, remove and reset the unit. 3. 4. Lock the rectifier into position by screwing in the captive retaining screws located at the bottom of the rectifier. Switch on the PSU and check the AC ON LED lights on the front of the PSU on the front of the rectifier. AC ON LED lights.
9-1
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10
--- A ---
--- C --C CB CE CISPR CL CUL Centigrade Circuit Breaker European Community International Special Committee on Radio Interference Current Limit Canadian Underwriters Laboratory
--- H --HL HV HVSD Hz High Line High Voltage High Voltage Shutdown Hertz
--- I --IEC IEEE In. International Electronics Commission Institute of Electrical and Electronics Engineers Inch
10-1
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--- L --Lb. LED LL LV LVD LVBD LVDS Pound Light-Emitting Diode Low Line Low Voltage Low Voltage Disconnect Low Voltage Battery Disconnect Low Voltage Disconnect Switch
--- M --M Max. MHz Mm Ms MTBF MV mVrms Meter Maximum Megahertz Millimeter Millisecond Mean Time Between Failure Millivolt Millivolt root root mean square
--- O ----- P --PF PFC PSU Power Factor Power Factor Correction Power Supply Unit
--- R --RFA RFI RH RMA Rectifier Failure Alarm Radio Frequency Interference Relative Humidity Return Material Authorization
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ATTACHMENT
Figure 1:
AC AC AC AC
Power Shelf
REV: 00
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A-1
ON
F OF
CL
FL
I-
I+
ON
F OF
FL
CL
I-
I+
ON
F OF
CL
FL
I-
I+
ON
F OF
CL
FL
I-
I+
O O O AC CL AC AC AC CL CL CL RF A RF A RF A RF A ON ON ON ON
Figure 1-1:
DETAIL "A"
REV: 00
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DC Output
Figure 1-2:
REV: 00
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A-3
Figure 1-3:
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A-4
13
25
ALAR M RELAY
14
Figure 1-4:
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A-5
Figure 1-5:
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A-6
Figure 2:
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A-7
Figure 2-1:
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A-8
Figure 2-2:
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A-9
Figure 2-3:
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A-10
Figure 2-4:
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A-11
Figure 2-5:
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A-12
Figure 3:
AC AC
ON F OF ON
REV: 00
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Power Shelf
A-13
AC
ON
F OF
CL FL O
I-
I+
CL FL O
I-
I+
F OF
CL FL O
I-
I+
CL RF
CL RF CL RF
AC
AC
AC
A A A ON ON ON
Figure 3-1:
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A-14
DETAIL "A"
Figure 3-2:
REV: 00
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A-15
Figure 3-3:
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A-16
Figure 3-4
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A-17
Figure 3-5:
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A-18
Figure 4:
Manual Float/ Equalizing Button High Voltage Shut Down Reset SMR RFA Warning Reset
RS232 Interface
LAN Interface
REV: 00
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A-20
Figure 4-1:
Manual Float/ Equalizing Button High Voltage Shut Down Reset SMR RFA Warning Reset
RS232 Interface
REV: 00
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A-21
Figure 5:
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A-22
REV: 00
Figure 6:
D/O A/D
SMR Current (1-5) Load Current (1) Batt. Temperature DC Voltage AC voltage Current Current Limit Signal
PWM
Voltage Output
A-23
SSP
EEPROM
D/I USART
SMR Fail Alarm Detection SMR Current Limit Detection Temp. Sensor Lock Off Breaker or Fuse Fail FL/EQU Exchange Signal SMR Fail Reset HVSD Alarm Reset
REV: 00
Figure 7:
L
Output Rectifier
N C
Input Fuse Inrush C.K.T. EMI Filter I/P Bridge PFC Boost Converter
FG
A-24
PFC Controller
Vo+ Vo-
Aux. Power
&
Driver C.K.T.
TAIPEI OFFICE 186 RUEY KUANG ROAD, NEIHU TAIPEI 114, TAIWAN, R.O.C. TEL : 886-2-87972088 FAX : 886-2-87972120 CHUNGLI PLANT 3 TUNG YUAN ROAD, CHUNGLI INDUSTRIAL ZONE, CHUNGLI, TAOYUAN HSIEN 320, TAIWAN, R.O.C. TEL. 886-3-4526107 FAX. 886-3-4527314